Installation & Maintenance Manual SOLO 11 0 -15 5 -199 & COMBI 155 -19 9 NOTICE - Customer must register unit within thirty (30) days of installation in order to gain warranty coverage. See Warranty Card for details. - Leave all documentation received with appliance with the owner for future reference. WARNING • To maintain the safety & longevity of your appliance, read and follow the maintenance schedule information throughout this manual.
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TABLE OF CONTENTS PRODUCT AND SAFETY INFORMATION .................................................................. XI CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS.................................................. 1 1.1. INSTINCT boilers - Code Compliance ....................................................................................... 1 1.1.1 Code Restrictions ................................................................................................... 1 1.1.2 Operating Restrictions ............
TABLE OF CONTENTS CHAPTER 4 - BOILER PIPING ................................................................................. 15 4.1. General Piping Requirements ............................................................................................15 4.2. Pressure Relief Valve ........................................................................................................ 15 4.3. Boiler Air Vent ..............................................................................................
TABLE OF CONTENTS 5.5. Hydro-Block ...................................................................................................................... 25 5.6. General Piping .................................................................................................................. 25 5.7. Thermostatic Mixing Valve ................................................................................................ 25 CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN ........ 27 6.1.
TABLE OF CONTENTS 9.5. Main Menu.........................................................................................................................47 9.6. EZ Setup ...........................................................................................................................47 9.7. Heating EZ Setup .............................................................................................................. 48 9.7.1 9.7.2 Select CH Demand (No outdoor sensor connected) ...............
TABLE OF CONTENTS 11.1. Final Checks Before Start-Up .................................................................................... 63 11.2. INSTINCT Start-Up ................................................................................................... 63 11.3. Check the INSTINCT and System ......................................................................................63 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 Check Boiler Piping....................................................
TABLE OF CONTENTS 17.15. Check Control Settings ...................................................................................................... 79 17.16. Perform Start-up and Checkout Procedures ...................................................................... 79 17.17. Check Burner Flame .......................................................................................................... 79 17.18. Check Flame Signal....................................................................
INDEX OF ILLUSTRATIONS AND TABLES Fig. 1 - All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Openings ....... 7 Fig. 2 -All Combustion Air from Outdoors Through One Permanent Air Opening ................................ 7 Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic ................................................ 8 Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts .............................................. 8 Fig. 5 - Accessories ............
INDEX OF ILLUSTRATIONS AND TABLES Fig. 38 - INSTINCT Control & Display Enclosures ........................................................................ 91 Fig. 39 - INSTINCT Combi Hydro-block ...................................................................................... 92 Fig. 40 - Front View INSTINCT Solo 110............................................................................................ 94 Fig. 41 - Right Side View INSTINCT Solo 110 .................................................
SAFET PRODUCT AND SAFETY INFORMATION IMPORTANT SAFETY INFORMATION FOR THE HOMEOWNER AND THE INSTALLER This manual contains important information with respect to the installation, starting up and maintenance of the appliance. This manual must be provided to the Homeowner, who will keep it in a safe place for future reference.
SAFET PRODUCT AND SAFETY INFORMATION DANGER HOT WATER CAN SCALD! Water temperature over 125ºF can cause severe burns instantly or death from scalds. WARNING • • • Should overheating occur or if the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance. Do not add cold make up water when the appliance is hot. Thermal shock can potentially cause cracks in the heat exchanger.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS INSTINCT boilers - Code Compliance The INSTINCT units must be installed by a qualified installer in accordance with the following: • All applicable local, state, national and provincial codes, ordinances, regulations and laws.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.2. Determining Product Location CHAPTER 1 NOTICE The INSTINCT is certified for indoor, conditioned space installations ONLY. Before locating the INSTINCT check for convenient locations to: • Heating system piping • Venting • Gas supply piping • Electrical service Ensure the INSTINCT location allows the combustion air/ vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS Recommended Clearances The INSTINCT is approved for zero clearance to combustibles, excluding vent and boiler piping. • • Boiler piping must be a minimum 1/4 inch from combustible materials. Reference the INSTINCT Vent Supplement for vent pipe clearance requirements. BEST PRACTICE 1.6. Residential Garage Installations CHAPTER 1 1.5. When installing the INSTINCT in a residential garage, the following special precautions per NFPA 54/ANSI Z223.
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2.1. Combustion Air Contamination WARNING If the INSTINCT combustion air inlet is located in anarealikely tocause or contain contamination, or if products which could contaminate the air cannot be removed, the combustion air must be repiped and terminated at another location. Contaminated combustion air will damage the unit and its burner system, and can result in substantial property damage, serious injury, or death.
CHAPTER 2 - COMBUSTION AIR & VENTING 2.2. Ventilation and Combustion Requirements - Direct Vent Air A Direct Vent appliance utilizes uncontaminated outdoor air piped directly to the appliance for combustion. CHAPTER 2 For Direct Vent installations involving only the INSTINCT, in which the minimum service clearances are maintained as listed in Section 1.5 on page 3, no ventilation openings are required, but may be necessary to equalize the air pressure with the outside.
CHAPTER 2 - COMBUSTION AIR & VENTING Methods of Accessing Combustion Air Into A Space - Category IV 2.4.1. Indoor Combustion Air NOTICE • The methods listed in this chapter for accessing IndoorCombustionAirassumethattheinfiltration rate is adequate and not less than .40 ACH. • For infiltration rates less than .40 ACH, reference the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for additional guidance.
CHAPTER 2 - COMBUSTION AIR & VENTING • CHAPTER 2 Two Permanent Opening Method. Two permanent openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided.
CHAPTER 2 - COMBUSTION AIR & VENTING In order to reduce the potential risks associated with indoor contaminates (see list in Section 2.1 on page 5), flammable vapors and tight housing construction with little or no infiltration air, it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes higher system efficiency by reducing heated indoor air from being exhausted from the house and replaced by cold infiltration air into thehouse.
CHAPTER 2 - COMBUSTION AIR & VENTING 2.7. Carbon Monoxide Detector Installation CHAPTER 2 Triangle Tube follows the recommended advice of CPSC and requires the installation of a minimum of two (2) carbon monoxide detectors with an alarm and battery back-up if hard wired; one in the mechanical room where the boiler is located and another installed in the area outside each sleeping area for all installations.
CHAPTER 2 - COMBUSTION AIR & VENTING Signage A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 2.8.4 Inspection.
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CHAPTER 3 - UNIT PREPARATIONS Handling Instructions 3.2. The INSTINCT is generally easier to handle and maneuver once removed from the shipping carton. To remove the shipping carton: Wall Mounting Installation The INSTINCT should be wall mounted using the wall mounting template and bracket provided with the boiler. The INSTINCT is not designed for floor installation. The INSTINCT is not to be installed on carpeting.
CHAPTER 3 - UNIT PREPARATIONS 3.4. Wall Mounting Guidelines The wall-mounting bracket is designed for stud spacing of approximate 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket. CHAPTER 3 1. For applications using wood studs, install the bracket using the lag screws provided with the boiler. Ensure both lag screws are installed securely in the studs. 2.
CHAPTER 4 - BOILER PIPING • • • • General Piping Requirements All plumbing must meet or exceed all local, state and national plumbing codes. Support all piping using hangers. DO NOT support piping by the unit or its components. Use isolation valves to isolate system components. Install unions for easy removal of the INSTINCT from the system piping. CAUTION Use a two-wrench method when tightening field piping onto the boiler piping connections.
CHAPTER 4 - BOILER PIPING 4.3. 4.4. Boiler Air Vent NOTICE • This boiler is supplied with a special automatic air vent that will provide reliable operation in purging air from the boiler. The hygroscopic cap supplied with the automatic air vent MUST remain tight at all times on the air vent body. The hygroscopic cap has a membrane which expands upon contact with water and seals the air vent until the membrane dries up due to new air forming in the air vent. CHAPTER 4 1.
CHAPTER 4 - BOILER PIPING Additional Limit Control If a separate Low Water Cut Off (LWCO) is required by the local jurisdiction or when the boiler is installed above the system piping, the following guidelines must be followed: • The LWCO must be designed for water installations, electrode probe-type is recommended. • The LWCO must be installed in a tee connection on the boiler supply piping above the boiler. • Wiring of the LWCO to the INSTINCT is done directly onto the low voltage terminal strip.
CHAPTER 4 - BOILER PIPING 4.7.1 Expansion Tank and Makeup Water 4.7.2 Diaphragm Expansion Tank Ensure the expansion tank is properly sized for the boiler volume: • 2 gallons [8 L] for the INSTINCT Solo 110 • 3 gallons [12 L] for the INSTINCT Solo 155 • 4 gallons [15 L] for INSTINCT Solo 199 Always install an automatic air vent on top of the air separator to remove residual air from the system. the system water volume, and the system water temperature. CAUTION 4.7.
CHAPTER 4 - BOILER PIPING See Fig. 15 on page 29 and Fig. 8 on page 17 through to Fig. 9 on page 18 and Fig. 21 on page 33 through Fig. 22 on page 34, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system using recognized design methods. 4.7.6 Domestic Hot Water System Piping See Fig. 21 on page 33 through Fig. 22 on page 34 for recommended piping to a DHW system.
CHAPTER 4 - BOILER PIPING 4.7.11 System Piping – Special Application If the boiler is used in conjunction with a chilled water/ medium system, the boiler and chiller must be piped in parallel. Install flow/check valves to prevent the chilled medium from entering the boiler.
CHAPTER 4 - BOILER PIPING System Supply System Return T P CHAPTER 4 Cold Water Fill Optional Instinct Combi Timesaver INSRKIT84 Fig. 11 - INSTINCT Combi Near Boiler Piping - Timesaver Manifold 4.8.1 Expansion Tank and Makeup Water Ensure the expansion tank is properly sized for the boiler volume: • 3 gallons [12 L] for the INSTINCT Combi 155 • 4 gallons [15 L] for the INSTINCT Combi 199 the system water volume, and the system water temperature.
CHAPTER 4 - BOILER PIPING 4.8.4 Sizing Primary Piping 4.8.8 System Piping – Radiant Heating See Fig. 15 on page 29 Fig. 11 on page 21 through Fig. 15 on page 26, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system using recognized design methods. The heat exchanger design of the INSTINCT Combi allows operation in a condensing mode.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING Domestic Piping Pressure Relief Valve 5.1.1 Standard Installation Install pressure relief valve onto the domestic piping as shown in Fig 16 below. Pressure relief valve (field supplied Domestic connection with Tee fitting Domestic Hot Water Supply 1. The INSTINCT is not supplied with a 150 psi [10bar] pressure relief valve and must be piped using a pressure relief valve connected as shown in Fig. 12 on page 23 2.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING Pressure relief valve discharge piping must not be: • Excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity. Directly connected to a drain. Terminate discharge piping within 6” from drain. Refer to local codes. Plugged, reduced or restricted. Subject to freezing. • • • 5.2.
CHAPTER 5 - INSTINCT COMBI UNITS - DOMESTIC PIPING 5.3. Water Hammer Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.
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CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN Installing Vent and Combustion Air 3. Tighten the condensate drain assembly retaining nut. WARNING DANGER The INSTINCT must be vented and supplied with combustion air as shown in the INSTINCT Vent Supplement, included in the installation envelope. Refer to instructions for parts list and method of installation.
CHAPTER 6 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 8. Route the tube from the condensate drain assembly to a floor drain or condensate pump. The condensate drain assembly must remain filled with water. Extended periods of non use or high temperature operation may allow the water to evaporate. Periodically check the water level in the condensate drain assembly and fill with water as necessary.
CHAPTER 7 - GAS PIPING Gas Flow External Manual Gas Shut Off Valve (Must Be Within 6” of the Boiler ) Ion-ic 186° F 156° DHW T ar g et = 18 6° F Tee Fitting Union Fitting Sediment Trap Min. Length of 3" Cap Fig. 15 - Recommended Gas Supply Piping Gas Supply Piping Connection NOTICE The gas supply piping must be installed in accordance to all applicable local, state, national codes, and utility requirements. 1. Install a 3/4” NPT for INSTINCT pipe union at the gas nipple, for ease of service. 2.
CHAPTER 7 - GAS PIPING 7.2. Natural Gas 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum. 7.2.1 Pipe Sizing Refer to Table 2 below for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated INSTINCT input (divide by 1,000 to obtain cubic feet per hour). • Table 1 is based on Natural Gas with a specific gravity of 0.
CHAPTER 7 - GAS PIPING 7.3. Propane Gas 7.3.2 Supply Pressure Requirements 7.3.1 Pipe Sizing WARNING • The unit was shipped with a propane conversion kit which is located on the top of the unit in the instructions packet. This kit includes all the necessary parts and instruction to perform the conversion from natural to propane gas. If this conversion kit is missing, please contact Triangle Tube Technical Support for missing kit before installing unit.
CHAPTER 7 - GAS PIPING Venturi Venturi interface Pipe to Venturi Air Inlet Gas Valve Air reference Hose Fig. 16 - Gas Valve / Venturi Assembly - INSTINCT Solo 110 Air reference Hose CHAPTER 7 Pipe to Venturi Gas Valve Air Inlet Venturi interface Venturi Fig.
CHAPTER 7 - GAS PIPING Air Inlet Venturi interface Venturi Air reference Hose Gas Valve Pipe to Venturi CHAPTER 7 Fig.
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CHAPTER 8 - WIRING 8.1. Internal Wiring WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause serious injury, or death. 8.1.2 Fuse Locations • • • The CTRLMax control module contains 3 internal replaceable 5A fuses as shown in Fig. 19 below. The top two fuses protect the INSTINCT as well as the CH1, CH2, DHW boiler outputs. A 2.
CHAPTER 8- WIRING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Boiler Pump ON ON ON CH1 Pump ON OFF OFF CH2 Pump OFF ON OFF DHW Pump OFF OFF ON Note.
CHAPTER 8 - WIRING INSTINCT COMBI PRESET PUMP CONFIGURATION Heat Call CH1 CH2 DHW Boiler Pump ON ON ON CH1 Pump ON OFF OFF CH2 Pump OFF ON OFF DHW Pump OFF OFF ON Note.
CHAPTER 8- WIRING lo Wiring Diagram K Blower G/Y 1 Gas Valve W Key = White BKW = Black = White R = Red G=BK Green = Black O= R = Red OrangeY = Yellow BL G= Green = Blue G/YO==Green / Yellow Orange GY = Grey = Yellow V =YViolet R Electrode V G 1 3 5 5 1 1 W 3 BL = Blue G/Y = Green / Yellow GY = Grey V = Violet BR = Brown BK BK W W W BK 1 3 1 P13 BK X10 P14 6 1 X9 6 1 X12 4 1 1 X1 12 1 Y X3 BK Flue Temperature Sensor BL Supply Temperature Sensor Y R 10 O R 1 BR BR X2 R
CHAPTER 8 - WIRING Combi Wiring Diagram Spark Generator Blower G/Y 1 Gas Valve R Electrode 1 Pump G 1 1 W W 3 BK W W BK 1 3 1 P13 BK 5 5 BK X10 P14 6 1 X9 6 1 X12 4 1 O BK 1 R GY X1 Diverter Valve 12 Y Y X3 R Flue Temperature Sensor BL Supply Temperature Sensor 1 R R10 O 1 BR BR X2 R Return Temperature Sensor BL Manual Reset Limit Auto Reset Limit O Y 14 G W BK R 3 Water Pressure Sensor DHW Turbine BK 3 G 1 G BK G W BK W X4 6 X5 1 4 X6 1 X7 3 1 1 v v
CHAPTER 8 - WIRING 8.2. External Wiring 8.2.1 General Requirements All field wiring must comply with: • National Electrical Code (ANSI/NFPA 70) for installations in the U.S., and any other national, state, provincial or local codes or requirements. • Canadian Electrical Code Part 1 (CSA C22.1) for installations in Canada. WARNING ELECTRICAL SHOCK HAZARD.
CHAPTER 8 - WIRING 8.3.2 Low Voltage Connections 8.3.4 Outdoor Sensor Wiring Line and Low Voltage wiring should be separated to prevent possible electrical noise on the low voltage circuits. Line and Low Voltage wiring should use separate electrical knockouts on the INSTINCT cabinet and should remain separated inside the INSTINCT. The Outdoor Reset function and Warm Weather Shutdown (WWSD) features require the connection of the included outdoor temperature sensor.
CHAPTER 8 - WIRING 1. Remove the factory-installed brown jumper wire at the Manual Reset Limit terminals that will accept the additional boiler limit. 2. Remove the factory-installed orange jumper wire at the Auto Reset Limit terminals that will accept the additional boiler limit. 3. Connect the external limit wires to the Manual Reset Limit or Auto Reset Limit low voltage terminals located on the lower right corner of the CTRLMax control module housing as shown in Fig. 25 on page 41. 8.3.
CHAPTER 9 - CTRLMAX OPERATION The CTRLMax Boiler Management System is designed to be flexible yet easy to use. CTRLMax monitors and controls the INSTINCT to provide heat as efficiently as possible. CTRLMax includes many advanced features: • Two central/space heating (CH) call inputs with separate outdoor reset curves. • Domestic Hot Water (DHW) call input with optional priority in INSTINCT Solo units and DHW priority in INSTINCT Combi units.
CHAPTER 9 - CTRLMAX OPERATION The menu system utilizes icons to represent each selection. The current selected menu is displayed as a reversed image with a text description shown at the top of the display. Menus can be entered by selecting the the desired icon (highlights) using the arrow soft keys and touching the soft key. The Home Screen icon at the bottom of each screen returns to the Home Screen when selected.
CHAPTER 9 - CTRLMAX OPERATION 9.3. Main Icons of CTRLMax display Home Screen • The Home Screen presents status information in a very user friendly way so that the current state of the boiler can be quickly accessed. • Screen backlight - it will illuminate when any soft key is touched, and remain illuminated for five minutes. • Screen brightness - it can be adjusted at the Home screen by touching and holding simultaneously the the • • • • and soft keys for 2 seconds.
CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages Standby - Indicates that the INSTINCT is ready to respond when a demand is received. CH Demand - A central heating call has been received. DHW Demand - A domestic hot water call has been received. CH/DHW Demand - Central heating and domestic hot water calls are being received simultaneously. Both calls are being satisfied simultaneously because domestic hot water priority has been disabled.
CHAPTER 9 - CTRLMAX OPERATION 9.6. Main Menu The EZ Setup menus provide a simple way to quickly customize CTRLMax for each installation. EZ Setup prompts the user to make selections which allows the INSTINCT to be setup very quickly without searching through long lists of settings and manually making adjustments. The Main Menu can be entered from the Home Screen by touching the soft key. The menu system utilizes icons to represent each selection.
CHAPTER 9 - CTRLMAX OPERATION 9.7. Heating EZ Setup Heating EZ Setup allows the installer to quickly customize the central heating settings for the application. 9.7.1 Select CH Demand (No outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH Demand is generated. Thermostat & Setpoint - A central heating call from a thermostat or zone panel will enable the INSTINCT and the setpoint will be fixed for central heating calls.
CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand(Outdoorsensorconnected) Select CH Demand prompts the installer to select how a CH Demand is generated. EZ Setup Heating EZ Setup Select CH Demand Thermostat & Outd. Curve – A central heating call from a thermostat or zone panel will enable the INSTINCT and the setpoint will vary with the outdoor temperature for central heating calls. After Thermostat & Outd. Curve is selected, the Select CH1 Reset Curve screen appears (see below). Thermostat & Outd.
CHAPTER 9 - CTRLMAX OPERATION 9.8. Domestic Hot Water EZ Setup - INSTINCT Solo Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. When Thermostat is selected in Select DHW Demand, a domestic hot water call from an aquastat or dry contact switch will enable the INSTINCT with a fixed setpoint for a domestic hot water call.
CHAPTER 9 - CTRLMAX OPERATION 9.9. Domestic Hot Water EZ Setup - INSTINCT Combi Units Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application DHW EZ Setup prompts the installer to select the DHW setpoint. EZ Setup DHW Setpoint prompts to enter the fixed setpoint temperature during a domestic hot water call. DHW EZ Setup Touch the or soft keys to adjust the temperature setpoint then touch to store the setting.
CHAPTER 9 - CTRLMAX OPERATION 9.11. EZ Setup Reset EZ Setup Reset allows reset of all EZ Setup settings back to the original factory defaults. See Chapter 13 on page 69 for the list of settings reset by this function. EZ Setup Follow the on-screen instructions to reset all EZ Setup settings. EZ Setup Reset EZ Setup Reset Press OK to restore factory settings, any other button to keep current settings. 9.12.
CHAPTER 9 - CTRLMAX OPERATION 9.13. CH/DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the INSTINCT. CH / DHW Operation Touch the or soft keys to select the CH or DHW icon, then touch to toggle between the enabled/disabled status. The status is displayed at the top of the screen. Heating Enabled Using the arrow keys, select the HOME or RETURN icon at the bottom of the screen to go back either to the home page or to the previous screen.
CHAPTER 9 - CTRLMAX OPERATION 9.14.1 Information Items CHAPTER 9 54 Information Item Description Boiler Status Displays the current operating state of the INSTINCT. This is the same as the status line on the home screen. Heating Call Displays if a central heating call is present. DHW Call Displays if a domestic hot water call is present. Boiler Firing Rate Displays the current firing rate of the INSTINCT. Ionization Current Displays the current flame ionization current from the ignitor.
CHAPTER 9 - CTRLMAX OPERATION Lockout History records the last eight lockouts. Six lines are displayed on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Boiler Information Lockout History Touch the or soft keys to scroll through the items then touch to select and get more details through the Lockout Details screen. The following information items are recorded at the time of a lockout: Lockout History 1.
CHAPTER 9 - CTRLMAX OPERATION 9.14.3 Manual Reset Lockouts CHAPTER 9 56 Code Lockout Message Description E1 Failed Ignition The burner failed to light after 5 ignition attempts. E2 False Flame Flame detected prior to ignition. E3 High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C]. E5 Blower Speed Blower is not at correct speed or speed signal is not being received by control module. E8 Flame Circuit Error Flame circuit test failed.
CHAPTER 9 - CTRLMAX OPERATION 9.14.4 Automatic Reset Blocking Lockouts Lockout Message Description E7 High Flue Temperature Flue temperature exceeds high limit. E12 Internal Control Fault EEPROM misconfiguration. E25 Internal Control Fault CRC check error. E32 DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit. E33 DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.
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Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.1. Boiler System Fluid Requirements NOTICE Requirements below must be met for warranty coverage of INSTINCT heat exchangers. A thorough cleaning of any existing system, using approved heating system cleaning agents is required prior to installation of the INSTINCT boiler. System should be treated with an approved inhibitor after filling for long term protection. WARNING Do not use petroleum-based cleaning or sealing compounds in the boiler system.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.1.7 Check and Test Antifreeze For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements. Due to the degradation of inhibitors over time, antifreeze fluids must be periodically replaced. Refer to the manufacturer of the antifreeze for additional instructions.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.2. Filling the Boiler System 1. Close the boiler drain valve located on the bottom of the unit and any manual or automatic air vents in the system. 2. Open all system isolation valves. 3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application. NOTICE Typical residential system fill pressure is 12 psi. System pressure will increase as system temperature increases.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.5. Check For Gas Leaks NOTICE WARNING • • Prior to start-up and during initial operation, check for a gas leak using a combustable gas detector. Do not proceed with the start-up if there is any indication of a gas leak. Any leaks found must be repaired immediately. Propane installations only - The propane supplier mixes an odorant with the propane to make its presence detectable. In some cases the odorant can fade and the gas may no longer have an odor.
CHAPTER 11 - START-UP PROCEDURES ► Read Chapter 9 on page 43 regarding the operation of the CTRLMax Boiler Management System. ► Verify the INSTINCT and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see specifications in Chapter 19 on page 93.. ► Verify Start-up Preparation items outlined in Chapter 10 on page 59 have been completed. ► Verify all electrical connections are correct and securely fastened.
FOR YOUR SAFETY, READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result, causing substantial property damage, serious injury, or death. A. This appliance does not have a pilot. It is equipped C. Use only your hand to turn the external manual gas with an ignition device which automatically lights valve. Never use tools. If the valve will not turn by the burner. DO NOT try to light the burner by hand.
CHAPTER 11 - START-UP PROCEDURES NOTICE 11.3.4 Verify Flame Pattern and Combustion NOTICE Combustion testing and adjustments must be performed by a qualified installer, service agency or the gas supplier. All combustion measurements must be performed with recently calibrated equipment (1 year max.) to ensure proper reading and accuracy. 2. Test for CO2 or O2 and for CO during high firing rate. The combustion readings must be within the range listed in Table 6 on page 66.
CHAPTER 11 - START-UP PROCEDURES CHAPTER 11 11.3.5 Measure Input - Natural Gas Only 4. Touch the 1. Ensure the boiler is firing at maximum firing rate. To manually place the boiler into high fire, reference Section 11.3.4 on page 65. 2. Operate the unit for approximately 10 minutes. 3. Turn off all gas appliances within the building, except the INSTINCT. 4. At the gas meter, record the time required to use one cubic foot of gas. 5.
CHAPTER 12 - OUTDOOR RESET CONTROL 12.1. Mounting the Outdoor Sensor 1. The exterior wall selected for mounting the outdoor sensor should represent the heat load of the building. Typically a northern wall will suit most buildings. 2. Ensure the outdoor sensor is shielded from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature readings. 3.
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CHAPTER 13 - EXTERNAL MODULATING CONTROL 13.1. Wiring the Modulating Controller Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to low voltage terminals X5-1&2 located at the bottom of the CTRLMax control module, as shown in Fig. 25 on page 41. This signal will both enable and modulate the boiler. No wiring is required at the thermostat terminals.
CHAPTER 13 - EXTERNAL MODULATING CONTROL CTRLMax Factory Settings (cont’d) HEATING SETTING DHW Operation MINIMUM SETTING MAXIMUM SETTING EZ SETUP RESET INSTALLER RESET Enabled Enabled ✓ Demand Type Thermostat N/A Thermostat DHW Boiler Setpoint 168°F [75°C] 168°F [75°C] 96°F [35°C] 188°F [87°C] ✓ ✓ DHW Setpoint 140°F [60°C] 140°F [60°C] 68°F [20°C] 168°F [75°C] ✓ ✓ N/A 125°F [52°C] 86°F [30°C] 140°F [60°C] ✓ ✓ ✓ DHW Warmstart Setpoint DHW Warmstart Hysteresis CHAPTER 13 N/A
CHAPTER 14 - CHECK-OUT PROCEDURES Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record in Chapter 15 on page 73. D Boiler system fluid chemistry checked and verified as outlined in Section 10.1 on page 59. D Boiler system was completely flushed to remove any debris/sediment. D Any automatic air vents placed within the system are open one full turn.
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CHAPTER 15 - INSTALLATION RECORD Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.
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CHAPTER 16 - MAINTENANCE SCHEDULES 16.1. Service Technician 16.2. Owner Maintenance At least on an annual basis the following maintenance should be performed by a qualified service technician: Periodically: • Check the area around the unit. • Check and remove any blockage from the combustion air inlet and ventilation openings. • Check the temperature and pressure gauges. Monthly: • Check vent piping. • Check combustion air inlet piping. • Check the pressure relief valve.
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CHAPTER 17 - MAINTENANCE PROCEDURES • WARNING The INSTINCT must be inspected and serviced annually, preferably at thestartoftheheating season, by a qualified service technician. In addition, the owner maintenance and care of the unit as outlined in Chapter 16 on page 75 and further explained in the INSTINCT User’s Information manual should be performed to assure maximum efficiency and reliability of the unit.
CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings • • Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers. Check and verify the vent termination and the combustion air intake are free of debris and obstructions. 17.8.
CHAPTER 17 - MAINTENANCE PROCEDURES • • • • • Inspect the ignition cable from the spark generator to the ignitor. Inspect the ground wire from the spark generator to the ignitor. Ensure wiring is in good condition and securely connected. Check ground continuity using a continuity meter. Replace ground wire if ground continuity is not satisfactory. 17.14. Check Control Wiring Inspect all control wiring. Ensure wiring is in good condition and properly connected. • • • • 17.15.
CHAPTER 17 - MAINTENANCE PROCEDURES 17.19. Check Combustion Levels • Refer to Section 11.3.4 on page 65 for measuring combustion levels and burner adjustments. • 17.20. Check Flue Gas Temperature • • • Manually place the boiler into high fire. See Section 11.3.4 on page 65 for procedure. Navigate to the Boiler Information Menu to observe the flue gas temperature. See Section 9.14 on page 53 .
CHAPTER 18 - REPLACEMENT PARTS WARNING • Replacement parts must be purchased through a local Triangle Tube distributor. When ordering a part, please provide the model number and description and/or part number of replacement part. • Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid improper operation or damage to appliance. • Contact Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors near you. Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS 1 Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig. 35 - INSTINCT Solo 110 Burner Components 12 It is essential to ensure during installation, maintenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.
CHAPTER 18 - REPLACEMENT PARTS Fig. 36 - INSTINCT Solo/Combi 155 Burner Components It is essential to ensure 12 8 1 during installation, maintenance or repair that items 12, 11 and 10 are correctly fitted between the blower and inlet adaptor. Failure to ensure correct fitting may result in serious injury, or death.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Boiler Model Fuel Input (Btu/h) Propane 110,000 19,375 – 155,000 24,875 – 199,000 19,375 – 155,000 24,875 – 199,000 Instinct 155 Solo Propane Instinct 199 Solo Propane Instinct 155 combi Propane Instinct 199 combi Propane Weight Lbs (Kg) Shipping Weight Lbs (Kg) 95% 83.5 (37.9) 99 (44.9) 124,000 95% 93.7 (42.5) 111.3 (50.5) 185,000 161,000 95% 103.8 (47.1) 120.4 (54.6) 143,000 124,000 95% 117.9 (53.5) 135.6 (61.5) 185,000 161,000 95% 128.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 40 - Front View INSTINCT Solo 110 A C B D E F G K I H J A CHAPTER 19 94 B C Item Boiler Width 3" Combustion Air Inlet 3" Vent Outlet Dimension inches [mm] 21 5/8 [550] 3 7/8 [100] 17 1/2 [445] D E F Vent\Com3/4" NSPC bustion Air Boiler Relief Connection Height Valve Height 2 1/4 [57] 5 1/8 [130] 26 [660] G H 1" NPT Boiler Supply 1" NPT Boiler Return 2 1/4 [57] 4 3/4 [120] I J K 3/4" Gas Conden- CondenConnection sate Drain sate Height
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 42 - Front View INSTINCT Solo 155 A B C D E F G H K I J CHAPTER 19 96 A B C Item Boiler Width 3" Combustion Air Inlet 3" Vent Outlet Dimension inches [mm] 21 5/8 [550] 15 3/4 [400] 4 3/4 [120] D 3/4" NSPC Relief Valve 2 1/8 [55] E F Vent\Combustion Air Boiler Connection Height Height 5 1/8 [130] 26 [660] G H 1" NPT Boiler Supply 1" NPT Boiler Return 1 7/8 [48] 2 3/4 [70] I J K 3/4" Gas Conden- CondenConnection sate Drain sate Height
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Instinct Solo Pressure Drop 25.0 Instinct 110S Instinct 155S 20.0 Pressure Drop (ft H2O) Instinct 199S 15.0 10.0 5.0 0.0 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Flow Rate (GPM) Graph 1 - INSTINCT Solo - Pressure Loss Through Boiler Note: Minimum allowable flow rate at full input: - 5 gpm SOLO 110 - 7 gpm SOLO 155 - 9 gpm SOLO 199 Instinct Combi Pressure Drop 40.0 15-78 SPD 1 Instinct 155C Pressure Drop (ft H2O) 35.
Additional quality water heating equipment available from Triangle Tube Maxi-Flo Pool and Spa Heat Exchangers • • • • Constructed of high quality corrosion resistant stainless steel (AISI 316) or titanium Specially designed built-in flow restrictor to assure maximum heat exchange Compact and light weight Available in 8 sizes to accommodate any size pool or spa SMART 316 Indirect Fired Water Heaters • • • • • • Exclusive Tank-in-Tank design Stainless steel construction Available in 7 sizes Limited LIFETI
